Expanded material and method of making same



SAME

June 30, 1959 R. N. STI-:EL

EXPANDED MATERIAL AND METHOD oF MAKxNG Filed Oct. l2, 1955 INVENToR. @06f/P7 /u Jfa BY AGENT United States Patent 'FEXPAN'DED MATERIAL YMETHODl 0F "MAKING SAME This invention relates to a method "of slvaging or reclaiming foamed or cellular-expanded or blown scrap, suchas latex .foam rubber scrap, and..more,particularly it relates to a method of converting latex foam rubber .scrap and the like into a more useful form in which it is fbound into a continuous mass by a curedfpolyurethane elastomer. The invention also relates to .an improved v:foamed elastic body comprising expanded or blown scrap, especially latex foam rubber scrap, permeated with an integrating network-` of polyurethane elastomer.

Conventional manufacture `and jprocessingy of blowny or expanded foam' or4 cellular plastic or elastomeric materials Mordinarily VresultY in the production of*considerable=-scrap fort'waste. Thus, in the-manufacturefof'foarn rubber or sponge rubber from natural'or'fsynthetic rubber'latexi by Lwhipping the compounded rubberlatex' into-a foamad vulcanizing the foam ina moldthere is almost-` inevitably `produced a `sizable vquantity 'f1scrap, :either because, for Yexample, the molded products nsometimes do -not have the 'exactlform desiredand haveL -to 'be discarded, lor because certain parts of the l molded shapes-:have to be cut laway -ortrimmed to provide a desired shape, Vthuspro'ducing trimmings and thelike of nondescript `sizesand shapes that'havelittle ifranyvalue assuch. *Sincethis* scrap represents l a considerable economic lWaste, there has been a continuingl desire to provide a more feasibleand more economical method ofconverting such scrap'into v'good Y quality sponge or -foam rubber sheets 0r1slabs=orarticles .ofzlother shapes.

iAccordingly, aprincipal "object of "the finvention 'is -to provide any economical fandeilicient method :f converting latex ffoam 4'rubber` scrap *fandv `the likeinto 'f useful-forms orz'shapes.

Still another object is the provision of an irnproved reclaimed f or salvaged :sponge --rubber scrap, Jort similar expandedsor 'blownfsplastic'r or elastomericv scrap.

The l `manner in which l"the :invention -realizes the 'iforegoing andzatlditional: objectsr and: advantages willtbernaiie manifest :in V"the following fdet'aile'd description, whichlis intendedizto be :readxwithtreferenceito the faccompanying drawing, wherein: -f

Fig. "l represents `in j:purely-1diagrammatic fashion a longitudinalf'elevationallview offani apparatus fsuitble for use in one-embodimentfof theinvention; and,

Fig...2:iswa1sectional lview ciffaJ mold containingrs'pon'ge ruhberzbeing molded in accordance with 'aimodiedpractice `:of` the invention.

.The invention contemplates initiallytdisintegratingfor shredding the latex foam rubber scrap, or other-*plastic orltelastomeric spongefscrap, 'i into frelatively s'mall'- more orzlessI uniform crumbsfor fgranules 1orf'th'eflike, Tywhichlrare thereafter treated-with alliquid;preparation comprising an uncured form f of :potentially elastomeric -polyesterpolysocyanate intermediate y reaction `product 'containing available `isocyanate groups. The-thus treated crumbs Iare thereafterrenclosedby a rsuitableconning means, such-as a'.mo1d,:;andrthe :massi while sofconiined` is treated? in "such mannerifasfto{curertheaisocyanate-containing intermediate 2,892,216 Patented .-Junel`30, 1959 ICC and .thereby convert lit into `a polyurethane elastomer.

Such cure is affected by subjecting the mass to the action of water vapor, and'for this purpose the mold or other .conning means is'provided with openingsso that `water vapor may be passed into the mass to'eiect-Ythecurefof the, polyester-polyisocyanate intermediate. The action Yof the water vapor on the available isocyanate` groups `inthe intermediate leads to a ser-iesof chemical reactions ythat result-ultimatelyin a cured or crosslinkedfelastomeric polyurethane, with concurrent evolution ofcarbon-.di

oxide gas,.so that the polyurethane'itself isperrneated with bubbles or poresorV cells formed' by such; gas. There is thus .produced lthroughout lthe Vmass of foam rubber Vcrumbs an integratingnetwork ofpolyurethane-foam or `sponge thatgives structure and form tothe mass andcon- 'fers on it a desirable quality of elasticity. The final Imass yis strong'and lirmlyV bonded together, while being elastic and resilientY and otherwise. possessed of the good physical propertiesdesired in a'foam or sponge. This yisparticularlyv unexpected in view of the yfact that it hasbeen obof glycol 'over the acid so 'that'the resulting ,polyester contains" terminal alcoholic' hydroxyl goups. Such` polyester maybe linear, or it'rna'ybe branched, therla'tter effect being achieved 'b'y including in'thepreparatin'a tralcohol, such .as tfrirnethyllpropa'ne Vor ltrime'thyllmethane. Usually Vsuch an amount of glycol is used'as tofgiveV a polyester having lahydroxyl number of '20i`t'o 120, and 'preferably`36to 67, and a'low Vacid'value 'less than2 and preferably1 less thanl. The molecular weight of 'the polyester preferably Vranges -from 170() to"3',0 040. The 'polyester "employedmay also be a polyester amide. Polyethers, especially polyetherglycols having terminalalcoholic 'hydroxyl groups,`may also be `used`in Aplace'f plyesters. Thepolyester or the like is reacted"with"a polyisocyanate, for 'eXample, triphenylmethane vrtriisocyanate, naphthalene 1,5-diiso`cyanate, `or `Jpgpdphenylmethane diis'ocya'nate, using a considerable molar excess, commonly from a"20% to a 250% andpreferably`irm a 50% 4to Val00% molar excess, ofthe polyis'ocyaii'ate over Ythat'farnount which would" be' required "toreact "with all "of tthe alcoholic hydroxyhgroups furnished'bythe polyester. The "reaction is. frequently V`affected 'by heatin'ga `mixture' of the polyester, 'or similar high'molfecl'ar weight 'compound having two or" more i alcoholic Ahyiclroxyl groups,.and the polyisocya'nate under anhydrous co'n'ditions `at an elevateditemperature, eg. 70l50 "C., "to forma soluble,runcured, material which is a polyurethane havingterminal isocyanate groups. i

l,The L'p'olyisocyanate's employed rin preparing", the'ipolyester-polyisocyanateY intermediate "are vl`generally v'dissocyanates, 'for example, polymethylene diisocya'iiates"snch as f e'thylene vdiisocyanate, fhexamethylene `diisocyana'l't'e and tetramethylene `diiso'cyanate; alkylene 'diisocyanates such as propylene-l,24diisocyanate; cycloalkylenejcliislocyanates such as `l;4;diisocyanatocyclohexane, `a`s Ewell as aromatic diisocyanatessuch as mandp-ph'enylene diisocyanate, toluene diisocyanata p,p' dipheny lvdiiso cya'nate and `15''naphthylene diisocyanate, in"whichc t e'gory we 'include aliphatic-aromatic diisocyanat'esfsiich as 11,p'1diphenylmethane diisocyanate andlphenyletlfane diisocyan'ate "Triisocyanates are also suitable, such as those having isocyanate groups attached to a trivalent hydrocarbon radical, whether an aliphatic, aromatic, or aliphaticaromatic radical as in butane-1,2,2-triisocyanate, ben- -'zene-1,3,5-triisocyanate, diphenyl-2,4,4 triisocyanate, diphenyl-4,6,4triisocyanate, toluene 2,4,6 triisocyanate, ethyl benzene-2,4,-triisocyanate and triphenylmethane 4,4,4" triisocyanate. Triisocyanates derived from corresponding substituted trivalent hydrocarbon radicals, such as monochlorobenzene-2,4,-triisocyanate may also be used. Many such polyester-polyisocyanate intermediate products, hereinafter referred to as the uncured polyurethane or polyurethane intermediate, can be thus prepared in the form of liquids utilizable directly for adcmixture with the shredded foam scrap, but if they are solids or unduly viscous liquids they are first dissolved -in a suitable volatile organic solvent such as carbon tetrachloride, methyl isobutyl ketone, benzene, methyl 'ethyl ketone, ethyl acetate, etc., to facilitate application. The viscosity of the polyurethane intermediate or a solution thereof may be reduced by heating it to an elevated temperature (e.g. 10G-200 F.) at the time of application, but in that event the intermediate should be protected from exposure to curing substances (including the moisture in the air), otherwise it may cure or set up prematurely, at least to the extent of becoming too viscous to spray or otherwise apply easily. Spraying under pressure of air or nitrogen is a preferred method of applying the intermediate to the rubber sponge particles. f As is well known, the polyurethane intermediate con- Ataining available isocyanate groups is capable of being cured by the action of various initiators of cross-linking, usually chemicals containing two or more hydrogen atoms available for reaction with the available isocyanate groups, notably water, or organic chemicals in general containing two or more OH and/or NH2 and/or -SH groups. Among such known curing agents may be mentioned polyamines, notably primary diamines, such as hexamethylene diamine, p-phenylamine diamine, p,p'diaminodiphenylmethane, o-dichlorobenzidine, and toluylenediamine; polyhydric alcohols, notably diols, such as butanediol; and polymercaptans such as hexamethylene dithiol. Compounds with mixed functional groups are also used, notably amino alcohols, such as amino ethanol and p-amino-phenylmethylcarbinol.

For purposes of the present invention the curing agent is appropriately utilized in the form of a vapor and is appropriately comprised for the most part of water, since water is unique among the foregoing agents in causing the release of carbon dioxide gas during the cure so that the polyurethane itself becomes blown or expanded in situ by the generated gas it is being cured within the massed crumbs of scrap rubber. Although the cure of the polyester-polyisocyanate intermediate to form the elastic polyurethane proceeds at room temperature, the reaction is slow and in practice we apply heat to the mass to accelerate the cure. Thus, by heating to temperatures of, for example, 212 to 300 F., substantial cure can be effected in as little as 5 to 10 minutes, but if less highly elevated temperatures are employed, e.g., 125 F., longer times, such as 1 to 3 hours may be required to effect appreciable cure. Exposure of the mass to open steam or to steam under pressure in an autoclave is a convenient way of supplying simultaneously the water vapor required for curing as well as the elevated temperature desired to shorten the time of cure. If desired, the cure may be further facilitated by adding to the mass at an appropriate stage small amounts of catalytic or promoting materials known to accelerate the cure of polyurethane rubbers, such as tertiary amines, e.g., dimethylamino cyclohexane, or di(diethylamino ethyl) adipate, etc.

disintegrated sponge or foam rubber scrap and liquid polyester-polyisocyanate intermediate is subjected to cure by exposure to steam in a mold or other confining means in which the rubber is confined in a definite volume during the cure, such definite volume most preferably being considerably less than the normal unconfned volume of the rubber sponge, that is, the mixture is substantially compressed before it is exposed to the curing conditions, and is maintained in this compressed condition during the cure. The mass is suitably compressed to about 1A to 3/1, and preferably about 1/2, of its original unconfined volume. This procedure results in partcularly desirable qualities in the final cured product, and by controlling the degree of compression during the cure considerable corresponding control over the final density of the foam can be achieved, over a relatively wide range.

The following examples will serve to illustrate the practice of the invention in more detail.

Example 1 Propylene glycol 11 Ethylene glycol 4.25 Adipic acid 11.25

In the course of the preparation of the polyester the unreacted glycol was removed by vacuum distillation, and the extent of the distillation determined the molecular weight of the polyester, as calculated from the acid number and the hydroxyl number. The polyester used in this example had a molecular weight of about 1800, a hydroxyl number of about 60 and an acid number less than 1.

The foregoing alkyd resin was mixed at a temperature of 85 C. with an excess of p',pdiphenylmethane diisocyanate in the proportion of 80 parts by weight of the polyester to 20 parts of the diisocyanate. A reaction occurred between the hydroxyl groups of the alkyd and the isocyanate groups to form a polyurethane intermediate characterized by the presence of unreacted isocyanate groups. This intermediate was a liquid which was soluble in the common organic solvents such as acetone.

A 70% by weight solution of the foregoing uncured polyurethane intermediate in methyl isobutyl ketone, to be utilized as a spray solution, was charged to a spray supply container 10, shown in Fig. 1, such supply being connected by a line 11 to a suitable source (not shown) of compressed air or other gas under pressure, the arrangement being such that the solution in the tank 10 could thereby be sprayed from the nozzle of a spray gun 12 connected to the tank.

The spray gun is mounted adjacent to a mixing device 13, comprised of a feed hopper 14 and a longitudinally Y extending cylinder 15 constructed of wire screening or In a preferred aspect of the invention the mixture of similar open material. A mixing screw 16 extends axially through the cylinder 15 and is adapted to be rotated by a suitable driving means 17 located at the rear of the mixing device.

Shredded vulcanized latex foam rubber scrap 18 is fed to the hopper 14, and is advanced through the mixing cylinder 15 by the action of the rotating screw 16. At the same time, the solution of uncured polyurethane intermediate contained in the tank 10 is sprayed by the spray gun 12 through the cylindrical screen 15 onto the sponge rubber crumbs 18 as they are advanced through the mixing chamber.

To lower the viscosity of the spray solution and thereby facilitate the spraying operation, the spray solution supply tank may be heated to a suitable temperature, e.g., F., by a suitable heating means (not shown).

The rate of advancement of the sponge rubber crumb 18 through the mixing device 13 and the rate at which the polyurethane intermediate solution was sprayed into the rubber crumbs were so regulated in this example that' from 5 to 10 parts by weight of the shredded latex foamregenerate `rreceivedtfl part-:by Vweighttofathezspray:fsdlution. Asthe ssprayedA particlesrareocarried `alongltheznixing;chamber fthey.=areztumbledibytheiactiorrothefeedscrewgandtthe liquid intermediate;4 is:V therebytedistributed tuniformly over lrtliefentiresurfaceof thercrumbs. Much'ofthelquid en- L ters into thev poressof the f -foamr'rubber .particles, tand.' the f. mixture. presents-fan essentially pdry,f`fowablef and-spreadable consistency.

'As the sprayedrcrumbsemergefrom the deliveryend of fthe mixingf device; theyxare deposited on a. conveyor y belt 1120, '.which proceedshorizontally A'beneath sa series of transverse .spreader-bars `S21, :which serve nto `spread .the

itreated foam rubberfcrunibsfoutinto `thegformof `a uniin'al to' whichthe niixtureiwill nonstick, and-it is preferably made of` alaminatefofzglassiibers and polyester. resin,

rsuch =as is described'inlUS. @Patent 2;667430fof \Wells. The conveyor vbeltis .perforated with 7'numerous small A desiredA thicknessiofthefnalsfheet. This spacing isf such pressed layer 22 of treated crumbs sandwiched -therebetween, then pass into an oven.. 26, within which an atmosphere of livesteam is maintained, 'the temperature being about }2121lF. *Uppera'nd lowvertguide rolls 27, 28 -maintainthez-desired spacing of theupper and llower-belts, .and the steam passes throughrthep'erforations:orgtsimilar (openings in` the belts into the -mass fof treated .foam crumbs. The speed at which the conveyor belts fare advancedis .such that `the treated ,foam jrubber crumb is :exposed to the steam for about 10.orl5 minutes. AAs a .resultof thistreatment the polyurethane intermediate lacquires` a substantialV amount of curen by the actionv of the w-aterr-onthe available isocyanateqgroups infsuch intervmediate, and at the same timefcarbondioxide isI generated by the chemical reaction so ,that theresulting polyurethane elastomer is spongy. The curedpolyurethane elastomer liformsla strong, .integratingnetworktwhich permeates and surrounds the latexfoam-,rubberparticles and is rmly adhered thereto, so that the 'sheet 22 now has the form -offa continuous,emtegrlmassfvvhichmay be wound up into a roll 30 as it comes frornftheema'ehine. xl?he-roll 30 may be dried subsequently to remove residual moisture, and to remove any remaining organic solvent.

Finished continuous sheets of latex foam rubber reclaim have been made by this method ranging in thickness from to 2" and in densities varying from 7 pounds per cubic foot to 13 pounds per cubic foot, depending on the amount of compression to which the particles are subjected during the steam cure.

Example 2 A polyester resin was prepared as in Example 1, as follows:

A mixture of 27 moles of adipic acid, 28 moles of diethylene glycol, and 2 moles of 1,1,1-trimethylolethane, plus 0.25% 'by weight of p-toluene sulfonic acid (based on the reaction mix) as catalyst, was heated for 18 hours under nitrogen gas, at temperatures of l80200 C., water vapor being removed as formed. At the end of the reaction vacuum was applied to strip out any Water remaining. The polyester thus obtained had a viscosity of 15,000 cps. (25 C.), an acid number less than 2, a hydroxyl number of 60, a molecular weight of about 2480, and an equivalent weight of 920.

100 parts of the foregoing polyester were mixed with 50 parts of a commercial diisocyanate known as Hylene TM (a mixture of toluene diisocyanate isomers comprising 80% of 2,4-toluene diisocyanate and 20% of 2,6-

toluene :diisocyanate Aiby'rweight). Anfexothermicrreaction took place, yielding'za.liquideuncured `polyurethane xiso'cyanate having an :excess of `.available visocyanate ngroups. This sintermediatetwas vlsprayed by;v means .1 of-sa `pressurized :hot-:tsprayflzsystem onto `shredded :latex scrap foam at the rate of 1 partfoftheipolyurethane intermedi- -flate by-:weig'ht-tolQiparts:ofthe-.shredded scrap. foam. lThe .uniformly-mixed .sprayed mass-:was .placed ina mold-35, las=shownin:Fig..f2,L. comprised. of .upper and lower hinged sections 36, 37 and containing inwardly.-projectingxcores :38. Numerous holes:39 wereprovided through the .Walls f of l the :fmold to .permit Yvapors topass therethroughv into lthe;mass of treatedflatex foam scrap containedztherein. ,Themold wasA placed 4in a-fsteamcharnber .atxa temperay"ture1oi2122F.sfor.l2 minutes. :The resultingrmolded -latcx foam scrapha'd desirable physical properties.

Example 3 parts by weight offatpolyesteras` in ExamplefZ :-'having:fahydroxylnumber of @64.4 and -an Iacid number :of. 2.5 "were `mixed with 21:4.parts by 4weight of toluene .diisocyanate 'This mixture was allowedto exothermand return: to room ftemperature. 'The resultant` prepolymer was mixe'd with an .equal Weightof methyl isobutyl'ketone f toemake a;50%;solution. This `50% Asolution wasthen -sprayed ontogshreddedfscrap foamata ratio of one .rpart l:bywveight of;prepo1ymer,solution to ten parts by weight zzf; shreddedscrap `foam. 'The sprayed shredded foam was compressed.5 0% and while compressedwassubject tofa 12minute steam cure at E212 F. Thc'entirel spray,

,.levelingfian'd cure operation was carriedfout onthezmaf chine I:mentioned ,iny the application.

Example 4 1 00 grams of a polybutylenee'therglycol'having 'amo- "lecular weight' of about 3100, a hydroxyl number of V"3*2'6 :and an acid number of less'thanl weremixed withBl grams of toluene diisocyanate to form aprepolymer. Thisprepolymer was then mixed with an equalweight of methylisobutyl ketone to make a '50% solution. '.This 'rprepolymer solution Ywas then sprayed onto scrap foam`at aratio of one part by weigh-t of'prepolymer solution'to sixg'parts byweight` of scrap latex foam. T he sprayed "."foam was s placed in a `mol`d`having a'loosetting cover "tofpermit the passage ffsteamfcompressed approximate- Ily50% anti subject't'o afteen minute steam cureat 212 F. A soft resilient rebonded foam mass resulted.

Example 5 Shredded latex scrap foam was sprayed according to Example 1 except that the sprayed mass was placed in a mold and sprayed with a 10% solution of N-methylmorpholine in water so that the top surface of the treated foam was uniformly wet. The mold was then tightly closed, the foam being compressed approximately 40%, and the mold placed in a hot air oven at F. The mold was heated in this oven for 45 minutes to alloiwr the moist atmosphere in the mold to thoroughly permeate the treated foam and react with the isocyanate intermediate. The result was a rebonded molded foam article exhibiting good resilience.

From the foregoing it will be apparent that the invention aords a convenient and economical method for converting otherwise comparatively valueless latex foam rubber scrap into shaped foam or sponge rubber articles that are valuable and highly useful. The resulting reclaimed foam rubber is stronger and more satisfactory in general than would be obtainable by using various rubber cements as the bonding agent. The present product has good tensile properties, particularly static fatigue, and it avoids the relatively high costs that would be incurred if it were attempted to bind the shredded latex foam scrap together with virgin latex foam.

-Having thus described my invention, what I claim desire to protect by Letters Patent is:`

mixture in a desired form, and subsequently converting the uncured polyurethane into a cured elastomeric sponge l which adheres firmly to the said shredded latex foam, whereby the said shredded latex foam is firmly bound together into an integral mass by the thus cured in situ polyurethane elastomer sponge.

4. A method of reclaiming vulcanized rubber latex foam scrap comprising shredding said scrap into crumbs, mixing said crumbs with a liquid comprising an uncured polyurethane elastomer intermediate, confining the mixture in a desired shape within a porous confining means, introducing steam into said porous confining means to convert said polyurethane intermediate within the mixture into a cured spongy elastomer, 4the said crumbs thereby being bound firmly into an integral mass by said l cured and foamed in situ polyurethane elastomer.

5. A method of reclaiming vulcanized rubber latex -foam scrap comprising shredding said scrap into crumbs,

mixing said crumbs with a liquid comprising a solution Aof an uncured polyurethane elastomer intermediate in a volatile organic solvent, compressing the mixture within a porous confining means having the shape of a desired article, exposing said porous confining means -to water vapor and elevated temperature to convert ythe said polyurethane contained in the compressed, confined mixture into a cured spongy elastomer, the said crumbs thereby being bound firmly into an integral mass by said cured and foamed in situ polyurethane elastomer.

6. A method of making a shaped body from vulcanized rubber latex foam crumbs comprising uniformly mixing said crumbs with a liquid comprising an uncured polyester-polyisocyanate intermediate containing available isocyanate groups, compressing said mixture within a confining means having the desired shape, supplying moist -heat to the mixture while so compressed and confined,

--said moist heat causing simultaneous cure and foaming of said intermediate whereby itis converted into a spongy elastomeric mass that serves to bind said crumbs together into a coherent elastic massof the desired shape.

7. A method of making a continuous elastic sponge blanket of definite thickness from vulcanized rubber latex foam crumbs comprising spraying said crumbs with a liquid composition comprising an uncured polyesterdiisocyanate intermediate containing available isocyanate groups, tumbling the said sprayed crumbs to distribute the said liquid uniformly throughout the crumbs, depositing the said crumbs on the surface of a porous conveyor belt, spreading the thus treated crumbs out on the belt to form a blanket of definite thickness thereon, advancing the said belt and blanket of treated crumbs thereon into engagement with a second porous belt spaced from said first mentioned belt by a distance less than the thickness ofthe blanket of treated crumbs, whereby the blanket of treated crumbs is compressed between the two said porous belts, advancing the assembly into la chamber containing steam, whereby the steam passes through the said holes in the belts into the said treated crumbs and acts on the said intermediate to simultaneously cure the intermediate and cause it to foam whereby the intermediate is converted into a spongy elastomer that serves to integrate the crumbs into a continuous blanket of the desired shape, and thereafter releasing the blanket fIom said confinement.

References Cited in the file of this patent OTHER REFERENCES Goggin et al.: Foamed Plastics, British Plastics, pages 528-536, December 1947. 

3. A METHOD OF MAKING A SHAPED BODY OF ELASTIC SPONGE COMPRISING MIXING SHREDDED RUBBER LATEX FOAM WITH AN UNCURED POLYURETHANE POLYMER, CONFINING THE MIXTURE IN A DESIRED FORM, AND SUBSEQUENTLY CONVERTING THE UNCURED POLYURETHANE INTO A CURED ELASTOMERIC SPONGE WHICH ADHERES FIRMLY TO THE SAID SHREDDED LATEX FOAM, WHEREBY THE SAID SHREDDED LATEX FOAM IS FIRMLY BOUND TOGETHER INTO AN INTEGRAL MASS BY THE THUS CURED IN SITUPOLYURETHANE ELASTOMER SPONGE. 